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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
1234567890

Design and Analysis of High Pressure Hydraulic Filter for

Marine Application

Toshin Momin1, RP Chandrasekar2, S Balasubramanian3, Dr. AM Junaid Basha4

1
Senior Research Fellow, DRDO, CVRDE, Chennai
2
Scientist 'C', DRDO, CVRDE, Chennai
3
Technical Officer 'C', DRDO, CVRDE, Chennai
4
Scientist 'G' Additional Director, DRDO, CVRDE, Chennai

E-mail: Momin.toshin@gmail.com

Abstract.Filter is a critical component in ahydraulic system for maintaining the cleanliness of

the fluid to required class level. InMarine applications very high reliable filter is required to
operate continuously in saline environment. Design anddevelopment of high pressure hydraulic
filter for Marine application is a challenging task. The design involves selection of special
materialsandstringent qualification tests as per International standards. The present paper
describes various stages of design and development of high pressure hydraulic filter for Marine
application.

1. Introduction
Hydraulic system of Marine vessel is used for various utility operation viz. sailing of vessel
andoperation ofcontrols. Thesystem oil cleanliness has to be maintainedby filters to achieveprolong
operationallife of valves and actuators. Filter to meet the system requirement has to be designedwith
utmost care to meet the specification requirement. Also, filter has to be designed to cater for high
reliability insevere environment conditions, like high salinity, high and low temperature cycle,
vibration, acceleration and shock.The filters used in marine vessels are subjected to shock up to 30g.
The design of the components for Marineinvolves special material, process planning, quality control
and stringent quality acceptance test procedure to International Marine standards.Most of the hydraulic
filters in modern marine vessel uses disposable filter elements made up of high strength glass fiber
media.The filter rating of such glass fiber media filters varies from 5 to 25 microns. The glass fiber
media has better contamination control and good service life over the conventional reusable stainless
steel mesh type media [1]. The detail design and analysis of the selected high pressure hydraulic filter
for Marine application are described and results of FEM analysis are presented.

2. High pressure hydraulic filter

Atypical Marinefilteras shown in Figure 1 considered for the present work is hydraulic pressure line
filter installed between the pump and other critical components of the system. Three such filters are
used for cruise, banal and alert lines. Pressure relief valve is provided before the filter to control the
pressure of the system. The filteris made of grey cast iron and coated with special coating to prevent
corrosion from marine environment.
Content from this work may be used under the terms of the Creative Commons Attribution 3.0 licence. Any further distribution
of this work must maintain attribution to the author(s) and the title of the work, journal citation and DOI.
Published under licence by IOP Publishing Ltd 1
Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
1234567890

The filter assembly shown in Figure 1

consists of filter head with in and out
ports.The filter is integrated with four
mounting holes at the top of head.Itis
designed with a handle type shutoff valve
which disconnects the element with the
fluid line to make it possible for safe
removal of element, without spilling the
oil.The filterhead is also equipped with
bypass valve, non-return valve (NRV),
differential pressure indicator (DPI), bleed
of valve and commuter valve. DPI is
having a thermal lockout arrangement,
which prevents faulty indication in case of
thickening of fluid in sub-zero temperature.
Drain plug is provided at the bottom of
bowl. The specifications of filter are given
in table 1.

Figure 1.Filter assembly

Table 1. Specifications of filter

Filtration rating β10(C)≥1000
Fluid flow rate 50 lpm
Working pressure 205 bar
Operating Temperature - 5°C to 100°C
System fluid FHARI SHELL 2841
Clean element pressure drop @ rated flow ≤ 0.3 bar
Assembly unit pressure drop @ rated flow 1.5 bar
Element differential collapse pressure 20 bar
Housing proof pressure 307 bar
DPI activation pressure 2 bar
Bypass valve cracking pressure 4 bar
Direction of flow OUT to IN

3. Design of high pressure filter

Filter design is a two-step process, first the filter element is designed to meet the specification
requirement, then housing is designed which accommodates the element to withstand the specified
pressure ratings with minimum pressure drop at the rated flow.

3.1 Filter element design

The filter element serves to trap contaminants. The filtration depends on the properties of the fluid
being filtered i.e. viscosity, density and the concentration of the solids in suspension. The filter
element is made out of glass fiber media of requisite filter rating and is supported with rayon paper and
stainless steel course mesh on both sides as shown in Figure2. Layers of media are pleated and wound
over a perforated stainless steel centre tube.The pleated filter media along with centre tube, top and

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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bottom covers are joined carefully with special

adhesive. Finally the fabrication integrity of filter
element is checked. The filter element assembly is
shown in Figure3.

While designing a filter element some basic

parameters like element pressure drop, critical
pressure for centre tube collapse and critical pressure
Figure 2.Pleated media
for centre tube buckling are calculated.

3.2. Estimation of clean element pressure drop

An important characteristic of the filter media is their resistance to the flow of fluid. This resistance is
a basic property of the filter material and is related to the physical structure of the filter element. The
pressure drop generated due to fluid passing through the filter element can be obtained from Darcy’s
equation as givenin equation 1 [2].

Q×µ×t
∆P = ⋯⋯
A×k×

Where:

∆p = pressure drop across the porous medium (N/mm2)

Q = fluid flow rate (mm3/s)
µ = dynamic viscosity of the fluid (Ns/mm2)
t = thickness of the filter material (mm)
A = filtering area (mm2) Figure 3. Element
k = permeability constant for the filter material (mm2) assembly
= d2 / 32
d = pore size (mm)
 = porosity

Pleated structure is used for the filter to provide large surface area in small envelope and thereby
keeping housing size to a minimum. Total filtrationarea can be calculated as,

Filtering area A = h x l ⋯⋯ (2)

Where
h = height of element (mm)
l = developed length of element (mm)
= 2xWxN
N = no. of pleats
W = pleat depth (mm)

Number of pleats (N) in filter element is obtained byconsidering pitch of 1.5 to 2mm at inner diameter
of element and is given as
π×D
N= ⋯⋯
Pitch

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
1234567890

Filter element pleat depth (W) is given as

D −D
W= ⋯⋯
where:

D1= outer diameter (mm)

D2 = inner diameter (mm)

As shown in Figure2, there are five sheets in filter element viz. two sheets of wire mesh, twosheets of
rayon fabric and one sheet of glass fiber media. Therefore total pressure drop across filter element will
be sum of pressure drop across all five sheets.
For the specified filter element the total pressure drop across all sheets is estimated as 0.2bar which is
less than the specified pressure drop of 0.3 bar.

3.3. Critical load for buckling of inner tube due to compressive load
During the extreme operating conditions the differential pressure rises very high across the filter
element. This will cause buckling of the inner tube of the filter element resulting in failure due to
collapse. Therefore it is essential to ensure the material selected and structural strength of the centre
tube along with welded joints of top and bottom covers to withstand the high compressive load. The
critical compressive load for the buckling of the centre tube is estimated from Johnson's equation as
given below [3].

h
Pcr = fy × A [ − fy ( ) × ] ⋯⋯
k π ×E

Where
π
Equivalent Area, A = . × {D − d }

D −d
Moment of Inertia, I = π [ ]

Least radius of gyration, k = √I⁄A

Load at Collapse Pressure (P),

π
P = . × [D − D ] × Collapse pressure ⋯⋯

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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Where:

Pcr = Critical compressive Load (N)

P = Load at collapse pressure (N)
D = Outside diameter of tube (mm)
d = Inside diameter of tube (mm)
h = Length of the tube (mm)
D1 = Outside diameter of element (mm)
D2 = Inside diameter of element (mm)
p = Differential Collapse pressure (N/mm2)
fy = Yield strength (N/mm2)
E = Young’s modulus (N/mm2)

For the specified filter, the critical load for buckling of inner tube due to
compressive load is obtained as 44500 N, which is more than the load of 2900 N at
collapse pressure. Hence the centre tube will not collapse under collapse pressure
load due to its strength. Figure 4.
Centre tube
3.4. Estimation of critical radial pressure for buckling of inner tube
The filter element is subjected to high radial pressures which will result in failure of the centre tube
along with top and bottom cover. Therefore it is important to estimate the critical radial pressure that
the filter element could withstand based on the specified collapse pressure rating. The critical radial
pressure should be more than the specified collapse pressure rating required for the filter. It is given
byequation 7 in the following [3].

π ×D×P
Pcr = ⋯⋯
l ×a

Where,

E×h
D=
× −µ

n×l
n =
π×a
.
l ×[ −µ ]
Z=
a×h

+n ×Z
P = +
n π ×n × +n

Where
h = Thickness of tube, (mm)
a = Inside radius of tube (mm)
l = Length of tube (mm)
E = Young’s modulus (N/mm2)
µ = Poison’s ratio
n = No. of modes

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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For the specified filter, the critical radial pressure is obtained as 696barwhich is more than specified
collapse pressure of 20bar, hence the centre tube will not collapse.

4. FEM analysis of centre tube

In order to study the pattern of stresses experienced by the centre tube under the specified operating
conditions, an FEM analysis has been carried out using ABAQUS software. The material of stainless
steel to AISI: 316L has been selected with the mechanical properties as shown in table 2.The FEM
analysis is discussed in the following.

Centre tube has been modeled as eight node

shell element for a sector of 45° such that one
period of the hole pattern is included in the
model. Fixed boundary condition is applied on
both end nodes where it is held at top and
bottom covers and the pressure load is applied
appropriately. A static analysis has been carried
out and the maximum stress in the centre tube is
computed as 97.5 N/mm2 for the working
pressure of 205bar. The stress pattern of the
filter element is shown in the Figure 5

Table 2. SS316L Material properties

Density 7900 kg/m3
Young`s modulus 200000 N/mm2
Poisson Ratio 0.3
UTS 540 N/mm2
(0.2%) Proof strength 400 N/mm2
Endurance limit 270 N/mm2 Figure 5. FEM analysis of centre tube

4.1 Filter housing design

The filter housing consists of a filter head and filter bowl. They are coated with protective coating to
prevent rusting from saline and humid environment of sea. The filter head provides housing for non-
return valve and shutoff valve mechanism.The handle type shutoff valve is made up of ball and seat
arrangement and is designed to serve leak proof joint upto maximum pressure of 1.5 times the
operating pressure. The ball is made from stainless steel and seat is made up of soft teflon material to
acquire perfect seating and leak proof arrangement.The filter bowl is used to house the filter element,
and is provided with drain port.

4.2 Filter bowl

The filter bowl is coupled with filter head with help of threads. During the replacement of filter
element, the bowl is withdrawn from the filter head and the new element is positioned with bowl and
reassembled.

The filter head and bowl are designed to meet the following pressure requirements:

Normal working pressure : 205 bar

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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Proof pressure :307 bar

Burst pressure :410 bar

In order to study the pattern of stresses experienced by the bowl under the specified operating
conditions, an FEM analysis has been carried out. Fixedboundary condition is applied on bowl top
portion where it is mounted. The maximum stress distribution on bowl of the filter is observed to be
239.3 N/mm2 as shown in Figure6.

Figure 6. FEM Analysis of filter Bowl

4.3 Filter bypass valve design
The bypass valve as shown in Figure7, limits the differential pressure across the element and can
provide uninterrupted flow when element is clogged. It is mounted in the filter head between the inlet
and outlet port.

Bypass Valve serves to:

1) Prevent collapse of the element
2) Ensures uninterrupted fluid supply to system till clogged element is replaced
3) Ensures that the differential pressure across the filter unit is within the specification

The poppet type bypass valve allows unidirectional flow

only.

The design requirement of bypass valve is to maintain a

pressure difference of not more than 4bar between inlet
and outlet ports. This set pressure is known as cracking
pressure of the valve. If the pressure difference between
inlet and outlet increases beyond set pressure of 4 bar the
force generated is enough to compress the spring thus
unseating the poppet from retainer and allowing the fluid
to pass.
Figure 7.Bypass valve
The dynamic friction acting between the seal and the stud is assembly

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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also being considered in the design calculation, since it contributes significantly in resisting to the
movement of poppet. The frictional force acting on O-ring seal can be estimated from the following
equation given below

f = µF ⋯⋯(8)

Where,
µ = Co-efficient of friction between seal and stud

Compressive or radial force (F) on seal is given by,

x . x
F = π × do × Do × E [ . ( ) + ( ) ] ⋯⋯
do do

Where

do = O-ring wire diameter (mm)

Do = O-ring diameter(mm)
E = Young's Modulus of elasticity (mm)
x = Seal deformation (mm)

Spring deflection per coil is given by,

×W×D
= ⋯⋯
G×d
Where,

D = spring coil mean diameter (mm)

d = spring wire diameter (mm)
G = Modulus of rigidity (N/mm2)
W = Axial Load on spring (when solid), (N)
τ×π×d
=
×D
τ = Allowable shear stress in spring material (N/mm2)
Tensile Strength × .
=
Factor of safety × Wahl′s factor k

k = Wahl's stress correcting factor

C− .
= +
C− C
C = spring index

= D/d

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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Force balance on poppet is done as shown,

Differential pressure force = spring pre-compression force + frictional force

Δp x Area = stiffness × precompression + f ⋯⋯

Figure 8. Forces acting on poppet

Figure 9. Spring load characteristics

For the specified filter, spring pre-compression required for accurate opening of valve at differential
cracking pressure of 4bar has been computed as 7 mm. Other dimensions of spring are selected from
standard design data book.

5. Conclusion
The high pressure glass fiber media cleanable filter required for hydraulic system of the Marine
hydraulic system has been designed with respect to pressure drop, critical radial pressure and
compressive load factors. An FEM analysis has also been carried out to study the level of stresses
experienced under collapse pressure. The critical radial pressure estimated is well within the collapse
pressure rating of the filter. The stresses observed due to the maximum working pressure are well
within the yield strength of the filter element. Hence the design of filter has been accepted for further
manufacturing and qualification testing for obtaining Navy certification.

REFRENCES

[1] Parker filtration's Handbook of Hydraulic filtration- Parker Hannifin, Hydraulic Filter Division,
Europe.
[2] Fluid mechanics and hydraulics by Dr. Jagadish Lal
[3] Design of filter element, M/s.Pal filter, U.K.

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Frontiers in Automobile and Mechanical Engineering IOP Publishing
IOP Conf. Series: Materials Science and Engineering 197 (2017) 012050 doi:10.1088/1757-899X/197/1/012050
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